Glueless dustless composite flooring material system
OwnerJohn B. Troendle, Mo Qifenginventors
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Abstract
A glueless dustless composite flooring material system providing PVC-based flooring having waterproof layers providing different qualities of hardness, wear-resistance, sound deadening, and decorative patterns, avoiding the use of moisture-susceptible compressed cellulose-based filler, with layers fused together, avoiding the manufacturing complexity and delamination risks of using glue or adhesive, with a quickly-cured, UV-cured top coating providing long-lasting high performance and shortening and simplifying the manufacturing, which can be done in a sheet-form, essentially continuous-run manner, with an ability to quickly and simply change the optional design printing and texturing produced, and having an optional underlayment layer.
Claims20
A glueless dustless composite flooring material product having a nominal top and bottom direction, the glueless dustless composite flooring material comprising:
- (i) a waterproof flooring base layer comprising a PVC resin mixture free of compressed cellulose material and glue and having compatible materials adapted to provide desired qualities in said flooring base layer, in use, said mixture formable by mixing, fusing, cooling, delivering, extruding, co-extruding, and mold forming;
- (ii) a waterproof flooring face layer comprising a decorative face sub-layer secured atop the flooring base layer and a wearing face sub-layer secured atop the decorative face layer, the decorative face sub-layer comprising a PVC decorative polymer film and the wearing face sub-layer comprising a PVC wear-resistant film;
- wherein said flooring face layer is fused by hot-melt overlaying to a top face of said flooring base layer and forms a unitary base-and-face subassembly;
- and
- (iii) a waterproof flooring coating layer comprising a UV-curable plastic resin and secured atop the wearing face layer, the flooring coating layer being formable by coating a top face of said base-and-face subassembly with at least one UV-curable plastic resin;
- wherein said base-and-face assembly and said flooring coating layer are fusible together and form a waterproof finished-large-sheet assembly;
- and
- wherein said finished-large-sheet assembly is profile-processable to desired size and shape, yielding multiple flooring segments of waterproof floor covering free of water-based materials.
A glueless dustless composite flooring material product having a nominal top and bottom direction, the glueless dustless composite flooring material comprising:
- (i) a waterproof flooring base layer comprising a PVC resin mixture free of compressed cellulose material and adhesive, said PVC resin mixture having compatible materials adapted to provide desired qualities in said flooring base layer, in use, said mixture formable by mixing, fusing, cooling, delivering, co-extruding, and mold forming, said PVC resin mixture comprising, by weight, between 20% and 35% polyvinylchloride, between 63% and 73% calcium carbonate, between 2% and 2.5% calcium/zinc heat stabilizer, between 1.6% and 2.5% chlorinated polyethylene elastomer, between 0.6% and 1.7% acrylic polymer modifier, between 0.2% and 0.25% internal lubricant, and between 0.32% and 0.62% high melting point polymer;
- (ii) a waterproof flooring face layer comprising a decorative face sub-layer secured atop the flooring base layer and a wearing face sub-layer secured atop said decorative face layer, the decorative face sub-layer comprising a PVC decorative film with an applied decorative pattern, and the wearing face sub-layer comprising a PVC wear-resistant film;
- wherein said flooring face layer is fused by hot-melt overlaying to a top face of said flooring base layer and forms a unitary base-and-face subassembly;
- and
- (iii) a waterproof flooring coating layer comprising a UV-curable plastic resin and secured atop the wearing face layer, the flooring coating layer being formable by coating a top face of said base-and-face subassembly with at least one UV-curable plastic resin;
- wherein layers of said base-and-face assembly and said flooring coating layer are fusible together and form a waterproof finished-large-sheet assembly;
- and
- wherein said finished-large-sheet assembly is profile-processable to desired size and shape, yielding multiple flooring segments of waterproof floor covering free of water-based material.
Dependencies are inferred from the claim text.